Split Sealed Bearing Module for Compact Tidal Turbine Nacelles
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Solution Overview
Problem
Tidal systems require a bearing arrangement that is reliable, has a long service life, and minimizes maintenance intensity, while also reducing the number of components to prevent component failure, which existing solutions fail to adequately address.
Innovation Solution
A sealed bearing module with an inner and outer ring, where one ring is designed as a split bearing ring, preloaded using a preloading element, and a compact design that can be easily integrated into the tidal system, reducing the need for separate rotor shafts and allowing for a plug-and-play installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate bearing components are used, then the bearing can provide adequate support, but the number of components increases leading to higher failure risk and maintenance needs
Solution Approach 1:
The patent combines multiple bearing components (inner ring, outer ring, rollers, cage, sealing elements, and preload mechanisms) into a single pre-assembled bearing module. This integration reduces the total number of discrete components in the tidal turbine system while maintaining all necessary bearing functions, thereby reducing potential failure points and simplifying maintenance.
2Ease of operation
If a complete pre-assembled bearing module is used, then installation is simplified, but the initial component count appears higher before assembly
Solution Approach 1:
The bearing module is pre-assembled and pre-tested at the manufacturing stage, with all components (bearing elements, seals, preload mechanisms) already integrated and configured. This preliminary assembly allows the module to be installed as a single unit in the tidal turbine, significantly simplifying on-site installation while ensuring proper configuration and reducing installation errors.
3Weight of stationary object
If the bearing module is designed to be compact, then the nacelle size and weight are reduced, but the bearing rings require closer spacing
Solution Approach 1:
The bearing module employs a nested arrangement where the rollers are contained within the inner and outer rings with minimal clearance. The cage nests within the roller assembly, and sealing elements are integrated into the ring structures. This nested configuration maximizes space utilization, creating a compact bearing module that reduces the overall length and enables smaller, lighter nacelle design.
4Ease of manufacture
If a split bearing ring design is used, then the bearing can be preloaded and assembled more easily, but the ring structure becomes more complex
Solution Approach 1:
The bearing ring is divided into two separable halves (split bearing ring design), allowing the bearing assembly to be opened and closed like a clamshell. This segmentation enables easier installation onto the rotor shaft and facilitates preload adjustment by separating the rings, while the two halves are subsequently bolted together to form the complete circular structure.
Data Source
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AI summary
A sealed bearing module (1) of a tidal power plant is disclosed, comprising a rotor with rotor blades arranged on a rotor hub and a rotor shaft supporting the rotor for transmitting a drive torque from the rotor hub to a gearbox or generator in a nacelle, wherein the nacelle has a housing (4) and wherein the bearing module has two bearing rings (6, 8), wherein at least one of the bearing rings is a split bearing ring with a first bearing ring part (6-1) and a second bearing ring part (6-2), wherein one of the bearing rings (8) has axially extending bores (12) for attaching the bearing ring directly to the nacelle housing, wherein the other bearing ring (6) is connected to a rotor shaft (2) and/or to the rotor hub and wherein the split bearing ring is preloaded by means of a preloading element (26).